Fused Filament Fabrication (FFF), also known as Fused Deposition Modeling (FDM), is an additive manufacturing process that uses thermoplastic filament as its primary feedstock. This technology offers numerous advantages, particularly in prototyping, functional part development, and distributed manufacturing. In recent years, FFF has seen strong expansion across a wide range of industries and is commonly used for applications such as engineering prototypes, end-use components, and manufacturing aids including jigs and fixtures. The maturity, accessibility, and relatively low cost of the technology have enabled the deployment of large-scale printer farms, making FFF the fastest-growing thermoplastic additive manufacturing process. TAFNEX™ Filament enables the production of high-performance parts designed to perform reliably in diverse environments.
FFF technology is widely available, ranging from compact desktop printers to professional and industrial systems, making it easy to integrate additive manufacturing into existing workflows.
Compared with large-format extrusion processes such as FGF, FFF enables the production of smaller components with fine features and a high level of dimensional detail, often allowing parts to be used without additional mechanical post-processing.
With no requirement for molds and the ability to swiftly change materials, FGF delivers a high level of flexibility. The process involves no physical conversion effort – just a digital change of the component geometry.
The comparatively low equipment cost of FFF makes it possible to scale production by operating multiple printers in parallel. Large printer farms can provide substantial production capacity while allowing capacity to be expanded flexibly as demand grows.
Professional FFF systems can integrate automated material handling, switching and drying solutions, helping to maintain consistent material conditions while enabling reliable and efficient printing workflows.
FFF uses thermoplastic filament that is continuously fed from a spool into a heated print head. The filament is melted in the nozzle and extruded as a thin strand, which is deposited along the contours defined by the software. By precisely controlling the movement of the print head, material is applied layer by layer to gradually build the component. Depending on the material and printer, the process can be carried out on an open-frame system or within an enclosed, temperature-controlled build chamber, while a heated print bed can be used to support adhesion and dimensional stability.
An FPV drone frame has been printed on an industrial FFF printer. For additional reinforcement, the component can be printed directly onto a net-shape TAFNEX™ Structural Sheet, combining additive manufacturing with continuous fiber reinforcement.
A robotic gripper has been printed using TAFNEX™ material on a desktop FFF printer, showcasing the potential for lightweight and functional components in robotics and automation.
Using TAFNEX™ MCAM203A filament, a motorcycle rear fender has been printed on an open-frame desktop FFF printer without a heated build chamber.